Modular Conveyor Assembly Cassette

ABSTRACT

A modular conveyor assembly employable with a materials mixing system is provided that includes an elongate frame supporting a motor driven axle, an idler axle, and a plurality of rollers supported in individual rotational fashion by the frame, and a belt and chain subassembly configured to be cycled rotationally about the axles and rollers, where the belt and chain subassembly includes first and second chains each attached along first and second sides of the belt, respectively, so that the belt and chains move in unison, and wherein the frame is configured to be detachable from a materials mixing system without the need to disassemble substantial components of the modular conveyor assembly.

BACKGROUND

The embodiments herein relate generally to a conveyor assembly fortransporting material. One application for embodiments of the conveyorassembly is, by way of example only, in the conveyance of aggregatematerials in a volumetric concrete mixing system, or other system thatrequires the transport of materials from one place to another within thesystem. The embodiments herein more specifically relate to a modularconveyor assembly cassette system configured to facilitate removal ofthe assembly system without the need to disassemble parts of theconveyor system.

In the context of volumetric concrete mixing systems, for example,multiple bins are provided for storing discrete components intended tobe mixed together for dispensing from the system a mixture of thecomponents in the form of concrete. Such systems are often transportableon the roadway, and serve to function as a ready-made supply of concreteby simply loading on-site (or loaded at a remote site and transported tothe desired location) the individual components that are then mixedtogether to dispense the concrete on-site. Often, aggregate conveyorsystems on volumetric concrete mixers must fit within a very tight spacein the mixer aggregate bin in order to allow the mixer body to fit on astandard heavy truck frame that is typically 35″ to 38″ wide across theworld.

Volumetric concrete mixing systems generally include a transportmechanism within the system to transport the materials from holding binswithin the system to an area where the components can be broughttogether and mixed for dispensing the mixture. The transport mechanismis often in the form of a conveyor assembly integrated into the overallmixing system. There are at least a few limitations with such systems.One, the conveyor assembly causes inefficient transport because it isconfigured to drag the belt and mating supporting cross bars across abase, which causes unnecessary wear and energy loss due to drag. Anotheris that the repair and/or replacement of the conveyor assembly withinthe mixing system requires at least partial disassembly of the conveyorassembly in order to remove it from the mixing system. Embodiments ofthe present system overcome at least one or both of these limitations,and possibly others as well.

SUMMARY

At least one embodiment of a materials mixing system is provided forstoring and mixing materials to create a mixture to be dispensed, thematerials mixing system comprising (a) a plurality of bins, eachconfigured to store one or more materials desired to be mixed with oneor more materials stored in one or more of another of the plurality ofbins, (b) a modular conveyor assembly configured for detachableengagement with a materials mixing system in which materials may betransported from one position to another position within the materialsmixing system, the modular conveyor assembly being configured so thatdetachment of the assembly from the materials mixing system does notrequire disassembly of components of the modular conveyor assembly tofacilitate repair and/or replacement of the assembly, the modularconveyor assembly being further configured to transport materials moreefficiently by reducing the friction of adjoining components configuredto move relative to each other; (c) a mixing assembly configured to mixthe desired materials in a fashion suitable for dispensing of thematerials when desired, and (d) a dispensing mechanism for deliveringthe mixture to a desired location.

In some embodiments, the materials mixing system may be portable, suchas a truck configured to carry the weight of the materials mixing systemto a site where the materials may be mixed and/or the mixture dispensed.Preferably, the modular conveyor assembly comprises a unitary belt andchain subassembly for delivering material to the mixing assembly andreturning to bring additional material in a cycling format. In someembodiments, the unitary belt and chain subassembly comprises a beltsufficiently durable to support the material to be transported butsufficiently resilient to permit cycling of the belt and chainsubassembly along a longitudinal axis of a support frame in adelivery-and-return fashion, and first and second chains each attachedalong first and second sides of the belt, respectively, so that the beltand chains move in unison; at least one of the chains configured toengage the motor-driven axle so as to permit cycling of the belt andchain subassembly for the transport of materials within a materialsmixing system.

In some embodiments, a modular conveyor assembly is provided that isconfigured for detachable engagement with a materials mixing system inwhich materials may be transported from one position to another positionwithin the materials mixing system, with the modular conveyor assemblybeing configured so that detachment of the assembly from the materialsmixing system does not require disassembly of components of the modularconveyor assembly to facilitate repair and/or replacement of theassembly. Embodiments of the modular conveyor assembly are preferablyconfigured to transport materials more efficiently by reducing thefriction of adjoining components configured to move relative to eachother by eliminating moving cross bars and/or employing frictionlesssupport materials upon which a chain or other moving parts may slide.

In some embodiments, the modular conveyor assembly comprises (a) anelongate frame configured to support at least one motor driven axle andan idler axle, both axles being aligned generally perpendicular to alongitudinal axis of the frame and generally parallel to each other; (b)a plurality of rollers supported in individual rotational fashion by theframe in general alignment with the motor drive and idler axles; and (c)a belt and chain subassembly configured to be cycled rotationally aboutthe motor drive and idler axles and the plurality of rollers, the beltand chain subassembly comprising a belt sufficiently durable to supportthe material to be transported but sufficiently resilient to permitcycling of the belt and chain subassembly along the longitudinal axis ofthe frame in a delivery-and-return fashion, the belt and chainsubassembly further comprising first and second chains each attachedalong first and second sides of the belt, respectively, so that the beltand chains move in unison; at least one of the chains configured toengage the motor-driven axle so as to permit cycling of the belt andchain subassembly for the transport of materials within the materialsmixing system. Preferably, embodiments of the elongate frame areconfigured to support in fixed but operational mode a substantialportion of the modular conveyor assembly components such that detachmentof the frame from a materials mixing system results in the modulardetachment of a substantial portion of the modular conveyor assemblycomponents, eliminating the need to disassemble some of the substantialportion of the assembly components.

BRIEF DESCRIPTION OF THE FIGURES

The detailed description of some embodiments of the invention will be ismade below with reference to the accompanying figures, wherein likenumerals represent corresponding parts of the figures.

FIG. 1A shows a schematic of one example application (by example avolumetric concrete mixer) of an embodiment of the present inventivemodular conveyor assembly cassette provided therein;

FIG. 1B shows the application and embodiment of FIG. 1A, with themodular conveyor assembly cassette embodiment shown partially removedfrom the example application of volumetric concrete mixer;

FIG. 1C shows the application and embodiment of Figure IA, with themodular conveyor assembly cassette embodiment shown fully removed;

FIG. 2A shows a rear schematic view of the application and embodiment ofFIG. 1A, with a rear portion of the one embodiment of the presentinventive modular conveyor assembly cassette shown;

FIG. 2B shows enhanced detail of the rear portion of the one embodimentof the present inventive modular conveyor assembly cassette shown withDetail Z in FIG. 2A;

FIG. 3A shows a schematic side view of one embodiment of the presentinventive modular conveyor assembly cassette;

FIG. 3B shows a cross-section of the embodiment of FIG. 3A across lineX-X;

FIG. 3C shows a cross-section of the embodiment of FIG. 3B across lineY-Y;

FIGS. 4A through 4D show perspective schematic views of embodiments ofthe present inventive modular conveyor assembly cassette, with varyingcomponents of the cassette displayed;

FIGS. 5A and 5B show details of an embodiment of a chain and beltassembly with an embodiment of the an inventive modular conveyorassembly cassette;

FIGS. 6A and 6B show further details of an embodiment of a chain linkand chain link tab that may be employed within a chain and belt assemblywith an embodiment of the an inventive modular conveyor assemblycassette;

FIGS. 7A through 7D show details of an embodiment of the support framefor an inventive modular conveyor assembly cassette.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

By way of example, and referring to Figures lA through 1C, oneembodiment of the present system comprises a materials mixing system 10comprising a plurality of material storage bins 12, a material transportassembly 14, a materials mixing assembly 16, and dispensing mechanism18, a dispensing mechanism position controller 20, and a mechanism forconnecting the dispensing mechanism 18 to the position controller 20. Inone embodiment, the dispensing mechanism 18 comprises a chute configuredto deliver concrete and the like, and the dispensing mechanism positioncontroller 20 comprises an extendable and retractable shaft to lower andraise the end of the chute. Numerous configurations are contemplated forthe dispensing of materials using dispensing mechanism and forcontrolling the position of the dispensing mechanism, not just thosedescribed and illustrated herein.

In one embodiment of the inventions herein, the materials mixing system10 may be portable by securing the components of the system describedabove to a transport vehicle 24. The materials mixing system maycomprise a volumetric concrete mixing system, or a system for mixing anddispensing other materials either of a construction nature or otherwise.

Referring specifically to FIGS. 1B and 1C, one embodiment of thematerials mixing system comprises a material transport assembly 14 thatis modular so that it may be removed almost substantially in itsentirety from the materials mixing system 10 without the need todisassembly the transport assembly. In one embodiment, such as thatshown in FIGS. 1B and 1C, and also particularly with respect to FIGS. 2Aand 2B, access to the modular assembly 14 may be at one end of thematerials mixing system 10 and can be removed in modular format byremoving the dispensing mechanism 18 and associated position controller20. In other embodiments, the modular transport assembly may be removedfrom the materials mixing system from a different location within thesystem.

As the materials transport assembly bears a great deal of operationalabuse, the assembly or parts thereof may need to be replaced fairlyfrequently. Or it may simply be that the assembly needs to be cleanedand tuned periodically. Providing an assembly that is modularfacilitates such activities. Referring to FIG. 2B, one embodiment of amodular materials transport assembly 14 comprises a frame 28 supportinga cycling belt 30. The system may also include skirts 34 that arelongitudinally positioned along the sides of the transport assembly tomaintain materials being transported on the best 30; in other words, tokeep the materials from falling off and creating dysfunction amongstmoving components of the system, or simply reducing the resulting yieldof the mixture.

Referring to FIGS. 3A through 3C, one embodiment of the modular materialtransport assembly 14 comprises a frame 28 for supporting the belt 30where a first chain 38 a and second chain 38 b are directly connected torespective sides of the belt 30 so that both the chains and the beltmove in unison in longitudinally cycling rotation through the assembly.Preferably, engagement of the chains to the belt may be accomplishedusing chain tabs 40 a, 40 b connected to chains 38 a, 38 b,respectively. Further details of the chains and tabs are discussedbelow.

It is contemplated that efficient movement of the belt/chain subassemblymay be accomplished by providing low friction materials in the form ofUHMW strips 44 and/or sheets available in the market place. Other lowfriction materials may be employed as well. In any case, the chain ridesatop such low friction materials 44 and slides more easily with a verylow coefficient of drag. Also, contributing to the efficient movement ofthe belt/chain subassembly may be accomplished by preferably supportingthe belt by a plurality of rollers 46, each rotationally andindependently supported by the frame 28 of the assembly. In oneembodiment, such as that shown in FIGS. 3A through 3C, the belt andchain cycle in unison to carry material, where the weight of thematerial is born by the rollers without the need for the material to beborne by cross bars that arc dragged along for the ride with the belt.Preferably, the belt/chain subassembly is driven by a motor-driven axle50 positioned laterally across the assembly frame 28, with a matingidler axle shaft 52 in general parallel fashion. By providing amotor-driven axle 50 and a mating idler axle shaft 52 in theconfiguration as shown, with proper tensioning in spacing, effective andefficient transport of material may be achieved. It is contemplated thatin some embodiments, for example those that are large and/or move greatloads of material, a plurality of motor-driven axles may be employed.Similarly, if so desired, a plurality of idler axles may be provided aswell. The exact configuration of the modular assembly therefore may bemodified to suit the load bearing needs of the materials mixing system,both in size, strength and overall configuration. Further details of atleast the embodiments of the modular transport assembly described hereinmay be appreciated by viewing FIGS. 4A through 4D, in which theabove-described components are shown in perspective view relative toeach other.

A beneficial feature of embodiments of the inventions herein, as alludedto above, is the unitary nature of the chain/belt subassembly. In thatregard, one such embodiment is shown in detail in FIGS. 5A and 5B, wherethe belt 30 and chains 38 a, 38 b cycle in unison, wherein the chainsare supported by chain rails 58 a, 58 b, respectively. The attachment ofthe chains to the belt may be accomplished by one of a number of waysthat those of ordinary skill in the art shall appreciate. In oneembodiment, referring to FIGS. 6A and 6B, each chain 38 comprises aplurality of links 60. Depending upon the design configurations desired,a tab 40 may be attached to one or more of the links 60 of chains 38 ina manner where the tabs extend inwardly toward the belt 30. Each tabcomprises a hole that may be aligned with a corresponding hole in theside of the belt so that the belt may be fastened to the tabs and,thereby, the chains. In one embodiment, attaching a tab 40 to everyother chain link 60 has shown to be an effective way to provideefficient unitary movement of the chain/belt subassembly. However, thoseof ordinary skill in the art may find that tabs are desired on everylink, or every third or fourth link, if so desired, or maybe even less.The belt 30 may be fastened to the chain link tab 40 by one of a numberof possible fastening systems, including elevator bolts.

Referring to FIG. 7A, the particulars of one embodiment of the frame 28of the modular transport assembly 14 may be appreciated. In that regard,the frame 28 may comprises side panels 54 a and 54 b with cross bars 56for structural stability. If so desired, as shown in FIG. 7Bspecifically, diagonal ties 72 may be employed to further buttress theframe against the forces borne by transporting heavy materials. In thatregard, other details may be appreciated.

In many conveyor systems, a mechanism for maintaining effective tensionon the conveyor belt is important in maintaining effective transport ofmaterials. Tension is adjusted to obtain the correct amount of tensionin the belt and chain in order for the chain to mesh with the drive andidler sprockets without slipping, but also to enable tension to beloosened when necessary to remove the chain from the sprockets. Suchmechanisms include take-up bearings on the idler shaft, where suchbearings may be adjusted to apply appropriate conveyor belt tension.Typically, the take up bearings for the idler shaft and the flangebearings for the drive roller shaft of a conveyor system are attached tothe outside of the main structural rail system for the volumetric mixer.This allows for more space to fit all the components but by definitionrequires that the bearing system be installed after the belt isinstalled and hence the belt cannot be tensioned until it is installedinside the aggregate bin.

In embodiments of the invention herein, the modular cassette conveyorsystem integrates a take-up bearing system within the conveyor frame.Referring to FIG. 7B through 7D, one embodiment of a compact modulartransport assembly may be described that includes an effective mechanismfor maintaining appropriate belt tension. In that regards, a take-upbearing assembly 62 is secured within the conveyor system frame 28 inwhich the assembly 62 comprises a bearing 64 for supporting the idleraxle 52. In one embodiment of the take-up bearing assembly 62, thetake-up bearing 64 is configured to linearly ride on a first and secondrail 70 a, 70 b, each supported by a support channel 72 a, 72 b,respectively. The particular configuration of the housing of the bearing64, as well as the particular configuration of the rails 70 a, 70 b, andsupport channel 72 a, 72 b, is not critical, and may be configured asdesired to make an effective and efficient modular conveyor system withappropriate tensioning functionality.

Linear movement of the take-up bearing 64 may be accomplished byemploying, at least in one embodiment, a length of threaded rod 66coupled to the housing of the take-up bearing 64 and leveraged against atake-up bearing plate 68 comprising a hole 67 through which the threadedrod 66 may pass and against which a nut (not shown) may be turned todraw the rod linearly through the take-up bearing plate hole 67 and,thus, move the take-up bearing 62 linearly along rails 70 a, 70 b. Ifdesired, the take-up bearing plate 68 may comprise a shoulder forsupporting the roller rail 32. In that regard, referring specifically toFIG. 7D, the side rail 54 a of frame 28 may be supported by a pluralityof gusset plates 76 shaped similarly to take-up bearing plate 68, eachwith a shoulder for supporting the roller rail 32.

The frame may be optionally reinforced with diagonal tie bars 78 inaddition to the cross-bars 56, if so desired. The frame preferably alsosupports a motor support bracket assembly 80 comprising individualcomponents 80 a, 80 b that may be made of any configuration suitable forsupporting a drive motor to rotate the drive axle. As with the idlershaft, the motor shaft is also preferably supported by a plurality ofbearings to provide efficient movement of the conveyor belt.

Persons of ordinary skill in the art may appreciate that numerous designconfigurations may be possible to enjoy the functional benefits of theinventive systems. Thus, given the wide variety of configurations andarrangements of embodiments of the present invention the scope of theinvention is reflected by the breadth of the claims below rather thannarrowed by the embodiments described above.

1-3. (canceled)
 4. A materials mixing system, comprising: a plurality ofbins; a modular conveyor assembly disposed beneath said plurality ofbins, said modular conveyor assembly operable to transport one or morematerials dispensed from said plurality of bins within said materialsmixing system, said modular conveyor assembly detachable as a unitarymodule from within said materials mixing system.
 5. The system of claim4, wherein said unitary module, including: a frame including a firstside panel opposite a second side panel; a motor driven axle; an idleraxle, each of said motor driven axle and said idler axle rotationallysupported in said frame proximate opposite frame ends; and a beltcircuitously disposed about said motor driven axle and said idler axle.6. The system of claim 5, wherein wherein said unitary module furthercomprises a first chain and a second chain, each of said first andsecond chains circuitously disposed about said motor-driven axle andsaid idler axle one of said first or second chains disposed along firstor second sides of said belt.
 7. The system of claim 6, wherein whereinsaid unitary module further comprises a plurality of tabs joined to oneor more of the links of said first or second chains, said plurality oftabs extend inwardly to connect to corresponding sides of said belt. 8.The system of claim 7, wherein wherein said unitary module furthercomprises a plurality of rollers discretely rotationally supported insaid frame in spaced apart relation between said motor driven axle andsaid idler axle.
 9. The system of claim 8, wherein said unitary modulefurther comprises an idler axle take-up bearing assembly operable toadjust belt tension.)
 10. The system of claim 4, further comprising amixing assembly configured to mix said one or more materials transportedby said modular conveyor assembly.
 11. The system of claim 10, furthercomprising a dispensing mechanism operable to deliver said mixture ofsaid one or more materials to a selected location.
 12. The system ofclaim 11, wherein said materials mixing system comprises a volumetricconcrete mixing system.